DuPont Suva DuPont ISCEON & DuPont Opteon Refrigerants. Neil Roberts DuPont Fluorochemicals April 2013
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1 DuPont Suva DuPont ISCEON & DuPont Opteon Refrigerants Neil Roberts DuPont Fluorochemicals April 2013
2 Agenda 1. DuPont and Refrigerants 2. Refrigerant Change Management 3. DuPont Suva 4. DuPont ISCEON 5. DuPont Opteon 6. Conclusions
3 Over 80 Years of Industry Leadership 1930s - Introduced the Safe and Efficient Freon Refrigerants making refrigeration available to all. 1990s Introduced the first Non-Ozone Depleting Suva Refrigerants to Replace CFCs and HCFCs 2000s Introducing the Easy Retrofit option ISCEON Refrigerants extending the life of CFC and HCFC designed equipment. 2010s Introducing Low GWP Opteon Refrigerants to further reduce the environmental impact of refrigerants.
4 Phase-Out of Ozone Depleting Substances and HCFC Consumption in Russia Implementation Year % Reduction from base year (1990) Max Consumption ODP Tonnes % % % % 0 Based on R 22 annual consumption the R 22 bank within installed refrigeration and A/C equipment is estimated at Thousand Tonnes. 4/21/2013 4
5 HCFC-Phase-Out Options Four Options Maintain operation using HCFCs= Risk!! Attention Replace with new equipment running on: ammonia hydrocarbons CO 2 HFC, e.g. Suva Keep running existing Keep running existing equipment equipment change of oil and only moderate further technical modifications are modifications are necessary: required: retrofit HFCs of the with DuPont TM Suva range, e.g. ISCEON 9 Series Suva 404A or Suva 407C Refrigerants
6 DuPont Suva Refrigerants Application DX Air Conditioning & Heat Pumps Commercial & DX Industrial Refrigeration DX Chillers Flooded Chillers & Low Pressure Chillers Traditional R22 R22 R502 R12 R22 R12 R123 New Equipment Suva 407C Suva 410A Suva 404A Suva 507A Suva 407A Suva 134a Suva 407C Suva 410A Suva 134a Comments Must be used with POE lubricants. Suva 410A only suitable for new equipment Suva 404A and Suva 507A have a relatively high GWP and energy efficiency reduces as the evaporator temperature rises. Suva 407A has a moderate GWP with good energy efficiency at low and medium temperature applications Suva 134a offers the best energy efficiency but where equipment footprint is important Suva R410A offers a good solution Suva 134a is currently the only option commercially available 4/21/2013 6
7 Refrigerant Comparison DX Air Conditioning Suva 407C has very similar properties to Freon 22. Suva 410A has a much higher cooling capacity, higher condensing pressure and higher compressor power but extremely good heat transfer coefficient gives a higher C.O.P. than Freon 22 and Suva 407C. Only suitable for equipment designed for Suva 410A. Evaporating Temperature = 5ºC, Condensing Temperature = 40ºC, Total Subcool = 7K, Total Superheat = 15K 4/21/2013 7
8 Refrigerant Comparison Low Temperature (-35ºC Evap Temp) Evaporating Temperature = -35ºC, Condensing Temperature = 40ºC, Total Subcool = 10K, Total Superheat = 35K, Liquid injection above 123ºC 4/21/2013 8
9 Refrigerant Comparison Medium Temperature (-15ºC Evap Temp) Evaporating Temperature = -15ºC, Condensing Temperature = 45ºC, Total Subcool = 7K, Total Superheat = 35K 4/21/2013 9
10 Refrigerant Comparison DX Chillers Evaporating Temperature = 5ºC, Condensing Temperature = 40ºC, Total Subcool = 7K, Total Superheat = 15K 4/21/
11 DuPont ISCEON refrigerants The DuPont ISCEON family of cost-effective, non-ozone-depleting retrofit refrigerants for CFC and HCFC enables the continued use of existing cooling units while avoiding expensive equipment replacement. Downtime due to the actual retrofitting process is minimal as in many cases the existing Alkyl Benzene or Mineral Oils can still be use. ISCEON refrigerants help facilitate compliance with environmental regulations, and afford an opportunity to demonstrate environmental responsibility with a more sustainable refrigerant solution.
12 ISCEON Refrigerants Retrofit Procedure 1. Obtain Baseline Data on Original Refrigerant 2. Recover old refrigerant 3. Change critical elastomeric seals 4. Change filter driers 5. Evacuate 6. Charge with selected ISCEON Alternative 7. Start-up and monitor 8. Leak Check, Label system, and optimize set-points if needed *ISCEON Retrofit Guidelines and ISCEON Retrofit Video
13 DuPont ISCEON Refrigerants Application DX Air Conditioning & Heat Pumps Commercial Refrigeration DX Industrial Refrigeration DX Chillers Traditional HCFC Alternative Zero ODP Retrofit Option R22 R22 ISCEON MO99 (R438A) R12 R22 R502 R22 R502 R12 R22 R401A,R401B, R402A,R402B, R403A, R408A, R409A, R409B R402A,R402B, R403A, R408A R401A,R401B, R409A R22 ISCEON MO49Plus (R437A) ISCEON MO99 (R438A) ISCEON MO79 (R422A) ISCEON MO99 (R438A) ISCEON MO79 (R422A) ISCEON MO49Plus (R437A) ISCEON MO99 (R438A) Centrifugal Chillers R12 ISCEON 39TC (R423A) Low Temperature (<-40ºC) R13B1 ISCEON MO89 4/21/
14 Refrigerant Comparison DX Air Conditioning Evaporating Temperature = 5ºC, Condensing Temperature = 45ºC, Total Subcool = 7K, Total Superheat = 20K 4/21/
15 Refrigerant Comparison Low Temperature (-35ºC Evap Temp) Evaporating Temperature = -35ºC, Condensing Temperature = 40ºC, Total Subcool = 10K, Total Superheat = 35K, Liquid injection above 123ºC 4/21/
16 Refrigerant Comparison Medium Temperature (-15ºC Evap Temp) Evaporating Temperature = -15ºC, Condensing Temperature = 45ºC, Total Subcool = 7K, Total Superheat = 35K 4/21/
17 Refrigerant Comparison DX Chillers Evaporating Temperature = 5ºC, Condensing Temperature = 45ºC, Total Subcool = 7K, Total Superheat = 7K 4/21/
18 ISCEON MO99 refrigerant: THE BASICS ASHRAE #: R-438A HFC blend: Zero ozone depletion GWP: 1890 (SAR) ASHRAE safety: A1 non-flammable UL: Certified Glide: 3-4K Can be topped off while servicing (do not mix with R-22) Compatible with MO, AB, and POE lubricants Approved by Bitzer, Emerson (Copeland Discus LT/MT supermarket) and Carrier for Chillers
19 MO99 The #1 Choice for Contractors Contractors select a refrigerant that.. Delivers performance similar to R 22 Equivalent efficiency Slight capacity decrease Allows easy conversion No oil change in most systems Proven in the field Thousands of retrofits OEM specified
20 BT data centre retrofitted to ISCEON MO99 Data Center of BT Group Plc in West London 11 R22-GEA Denco close control systems, each 74kW capacity Service Contractor: Temperature Control Ltd. Manchester First step: Retrofit of one 17-years-old unit to ISCEON MO99 Closely match of pressure, temp., enthalpy and mass flow One single oil-change to POE before the retrofit R22-removed, all critical seals replaced, filter drier changed Finally minimal adjustment of TXV All 11 systems now retrofitted to MO99, due to the positive experiences
21 On site Refrigerant Conversion for HVAC Equipment Carrier completed a rigorous evaluation of 17 different retrofit refrigerant solutions and selected ISCEON MO99 (R438A) as their #1 and only choice for their service offering!
22 Roof Top Heat Pump in Phoenix ISCEON MO99 - Retrofit of R-22 roof-top heat pump in Phoenix. North Valley Mechanical converted over 50 units to R-438A until April Service company is very satisfied with the easiness of retrofit and the performance after.
23 Montreal Protocol accomplishments Thousands of tonnes Estimated Global Fluorochemical Consumption Transitions due to Ozone Regulations CFCs? Transition due to Climate Regulations? HCFCs HFCs A5 Countries Other Refrigerants Refrigerants Foam Expansion Solvents Propellants Fire Extinguishants
24 Refrigerant Selection Best Balance of Properties for each Application Zero ODP, Low GWP Favorable Toxicity No or Low Flammability Safety and Sustainability System Energy Efficiency + Capacity Performance Cost to Use First Cost + Operating + End of Life = Total Cost to Use ** ** Impacted by maturity of technology Timing of Commercial Availability
25 What are HFOs? CFC HCFC HFC HFO Chloro-Fluoro-Carbon Hydro-Chloro-Fluoro-Carbon Hydro-Fluoro-Carbon Hydro-Fluoro-Olefin HFO-1234yf CF 3 CF=CH 2 Unique properties: Stable in operating system Not stable in atmosphere = low GWP Efficient performance
26 HFO-1234yf (CF 3 CF=CH 2 ) GWP 4 Same operating conditions as 134a (similar P/T curve) Thermally stable under extreme use conditions Cooling capacity and energy efficiency comparable to R-134a Pressure, MPa Vapor Pressure 134a yf Temperature, o C R-134a HFO-1234yf Mildly flammable Formula CH 2 FCF 3 CF 3 CF=CH 2 Molecular Weight ODP 0 0 GWP 100 (AR4) T Critical Point 102 ºC 95ºC Boiling Point -26ºC -29ºC
27 Auto OEM industry HFO-1234yf SAE International HFO-1234yf accepted for use in automotive AC - Safe for use; low environmental impact HFO-1234yf selected by Auto OEMs globally to meet EU MAC Directive
28 ASHRAE Product Safety Considerations ASHRAE Classification Examples: Highly Flammable (3) A3 B3 Propane Isobutane A3 A3 Flammable (2) A2 B2 R-152a A2 Mildly Flammable (2L) HFO-1234yf 2L Practically Non-Flammable (1) A1 B1 R-134a A1 Low Toxicity (A) Higher Toxicity (B)
29 HFO 1234yf (5,000 10,000) NH3 ( ) R 32 (30 100) 2L Propane Isobutane DME Ethylene HFO 1234yf High Minimum Ignition Energy Difficult to Ignite
30 Standards Activity in Europe ASHRAE Class 2L Safety standards -- updating for 2L: -- ISO-5149 Complete IEC Revisions underway Impact on market: -- Larger charge sizes allowed than Class 2 or 3 refrigerants (e.g. hydrocarbons) -- Allows 2L use in small to medium A/C and refrigeration systems (e.g. Self contained and condensing units) - charge limits may be set based on room size
31 DuPont Opteon Refrigerants The Optimal balance of properties GWP reduction over current HFCs Improved environmental sustainability Efficient performance
32 DuPont Next Generation Refrigerants for Stationary AC & R Leading Candidates
33 Opteon Low GWP Replacements for R 404A Leading Candidates DR-33 GWP ~ 1400; 65% reduction vs R-404A Close performance match to R-404A Non-flammable; for retrofit and new systems 65% 84% 94% XP10 DR-7 GWP ~ 600; 84% reduction vs R-404A Close performance match to R-134a; for retrofit and new systems Non-flammable; preferred for hybrid CO2 cascade systems GWP ~ 250; 94% reduction vs R-404A Close performance match to R-404A Mildly flammable (ASHRAE Class 2L expected) For smaller charge size equipment (condensing units, self-contained)
34 Stationary AC&R Application Development Application Current Near Term Long Term Commercial Refrigeration R 134a R 134a HFOs, XP10 R 404A/507 R 407A DR 7, DR 33 CO 2 CO 2 CO 2 DX Air Conditioning/Heat Pumps Chiller R 410A DR 5, R 32 R 134a R 134a HFOs, XP10 R 123 (Past) DR
35 XP10 Evaluation in Supermarket - Hybrid System - Retrofitted from R-134a Medium Temp; CO 2 in Low Temp - Running for two years
36 Annual Energy Use and TEWI Comparison TEWI reduced by 48% for XP10-CO2 hybrid system versus R-404A Source: Hauser presentation, EHI Conference, October, 2010
37 Albert Heijn Assendelft/ Netherlands Hybrid System and Heat-Pump XP10 / CO 2 Cascade & R134a HP Installer Company: Frimex TBI Coordination by P.W. Vlaskamp B.V. Refrigeration Consultancy
38 Stationary AC&R Application Development Application Current Near Term Long Term Commercial Refrigeration R 134a R 134a HFOs, XP10 R 404A/507 R 407A DR 7, DR 33 CO 2 CO 2 CO 2 DX Air Conditioning/Heat Pumps Chiller R 410A DR 5, R 32 R 134a R 134a HFOs, XP10 R 123 (Past) DR
39 Reach-In Freezer Drop-in Test DR-7, DR-33 Ambient T = 32 C Energy Consump (kwhr/day) Energy Cons Rel to R404A Ev Exit SH (F) Mass Flow Rate (lb/hr) Suct Press (Psia) Disch Press (Psia) Comp Ratio R404A % DR % DR % Comp Disch Temp ( F) Ambient T = 24 C R404A % DR % DR % Ambient T = 21 C Energy consumption equivalent or lower than 404A R404A % DR % DR % Source: DuPont Systems Lab Test Results
40 Low Temp Reach-in & Walk-in Test Results DR-7 112% 110% % EER Low-Temp Reach-in & Walk-in Tests 108% 106% Reach-in 24ºC amb Walk-in 35ºC amb 104% 102% Walk-in 15ºC amb Walk-in 15ºC amb + 180# Head Pressure Control 100% % Capacity 85% 90% 95% 100% 105% 110% 115% 120% 98% Energy efficiency and capacity superior to 404A Source: DuPont testing partner system test lab results data used with permission
41 Condensing Unit Low Temp Test m open frozen food display case designed for R-404A, fully loaded with food simulator - Reciprocating compressor with POE 32 oil - Refrigerant charge size ~3.8 kg, adjusted based on liquid density Open Display Case in Indoor Room -Tested per ASHRAE Standard Tested R-404A and DR-33 at two ambient temps: 28ºC and 35ºC - Only minor TXV adjustment made (1.6 turns closed) - Average food simulator temp controlled at - 16ºC, average evaporator temp -34ºC Condensing Unit in Outdoor Room
42 Condensing Unit Test Results - DR-33 showed 3-4% lower energy consumption - similar pressures and compression ratio - modest increase in discharge T and slightly lower mass flow rate Ambient T = 28ºC Energy Consump (kwhr/day) Energy Cons Rel to R404A Mass Flow Rate (kg/hr) Suct Press (kpa) Disch Press (kpa) Comp Ratio R404A % DR % Comp Disch Temp (ºC) Ambient T = 35ºC R404A % DR %
43 Stationary AC&R Application Development Application Current Near Term Long Term Commercial Refrigeration R 134a R 134a HFOs, XP10 R 404A/507 R 407A/F DR 7, DR 33 CO 2 CO 2 CO 2 DX Air Conditioning/Heat Pumps Chiller R 410A DR 5, R 32 R 134a R 134a HFOs, XP10 R 123 (Past) DR
44 110% 105% 100% 95% 90% 85% 80% Cooling Comparison: DR-5 vs R410A 7.4 kw R-410A inverter mini-split 100% 100% 96% 103% 100% 98% 410A DR-5 DR-5 Cap Match Capacity COP Performance similar to R 410A Source: Reduced GWP Refrigerant Evaluations for AC and Heat Pump Applications ; ICACR Pyongyang, Korea 7 July, 2011; Thomas Leck DuPont Refrigerants, Younghwan Ko LG Electronics, Inc, Jongchul Ha LG Electronics, Inc
45 DuPont Opteon Refrigerants Commercial Timing for Stationary AC & R HFO Production Opteon yf (HFO-1234yf) Interim Production (Focus on MAC + ACR Testing) Large Scale Commercial Production DR-2 Pilot Plant Large Scale Commercial Production Market Development/Demand for Stationary Applications Opteon yf, DR-2, HFO Blends (e.g. DR-5, DR-7, XP10) Application Development Commercial Demand
46 DuPont Opteon Refrigerants Next Steps Monitor F-Gas revision and assess market interest and timing for Stationary AC & R Build/expand production capacity for HFO-1234yf to support new F-Gas Regulation requirements Continue application development for Stationary AC & R Assess Total Cost of Ownership (TCO) versus other options Continue to develop codes & standards for 2L refrigerants (smaller charges)
47 Conclusions o A Full Range of Non-Ozone Depleting HFC Refrigerants 4/21/2013 PRESENTATION TITLE 47
48 Thank You Disclaimer: The information set forth herein is furnished free of charge and based on technical data that DuPont believes to be reliable. It is intended for use by persons having technical skill, at their own risk. Since conditions of use are outside our control, we make no warranties, expressed or implied and assume no liability in connection with any use of this information. Nothing herein is to be taken as a license to operate under, or a recommendation to infringe any patents or patent applications.
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